Optimization of brewing and beverage packaging process using V-graph analysis

One of the features that should be considered when focusing on increasing company profits is the dynamic process that regulates a production line. Indeed, poor packaging line efficiency causes limited production capacity generating high levels of rework. This work presents the implementation of a line balancing optimization using V-graph method on a production line of an important Italian beverage company. In particular, the analysis of throughput changes and throughput levels on different machines of the bottle packaging line is carried out. The concept of V-graph method is to ensure that the bottleneck asset is fed with material at a rate greater than it can cope with in order to enhance the continuous flow of goods within the production line. To fulfill this task, two different studies are carried out: the first is a zero-cost solution only based on asset throughput optimization without modifying the production line layout. Instead, the second study involves structural modification to the packaging line which consists of generating buffers within the line by increasing the capacity of conveyors located between two successive machines. Finally, a feasibility analysis is performed to determine the best of the two proposed solutions by evaluating parameters such as payback period and return of investment (ROI).